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Capacity failure rate based opportunistic maintenance modeling for series-parallel multi-station manufacturing systems

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  • Zhou, Xiaojun
  • Shi, Kailong

Abstract

In a series-parallel multi-station manufacturing system, the failure of the series station may cause the loss of the whole system capacity, while the failure of the parallel station only causes the loss of part of the system capacity. To quantitatively describe the impacts of these comprehensive failure modes on the system capacity, an evaluation index called Capacity Failure Rate (CFR) is developed based on the universal generating function. Then, a rule-based Opportunistic Maintenance (OM) policy is proposed with the CFR involved. The Preventive Maintenance (PM) opportunity occurs whenever one of the stations reaches its optimal PM interval or the CFR of the system reaches the threshold. A variable maintenance time window is developed to group the PM activities of the stations. The optimal PM scheme of the system is obtained by maximizing the maintenance efficiency of the system, defined as the availability of the system capacity driven by per unit maintenance cost, within the whole maintenance scheduling horizon. Finally, numerical examples are illustrated to show the application of the CFR and the advantage of the proposed OM policy.

Suggested Citation

  • Zhou, Xiaojun & Shi, Kailong, 2019. "Capacity failure rate based opportunistic maintenance modeling for series-parallel multi-station manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 181(C), pages 46-53.
    • Handle: RePEc:eee:reensy:v:181:y:2019:i:c:p:46-53
    DOI: 10.1016/j.ress.2018.09.007
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    Cited by:

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    4. Li Li & Yong Wang & Kuo-Yi Lin, 2021. "Preventive maintenance scheduling optimization based on opportunistic production-maintenance synchronization," Journal of Intelligent Manufacturing, Springer, vol. 32(2), pages 545-558, February.
    5. Li, Yaping & Xia, Tangbin & Chen, Zhen & Pan, Ershun, 2023. "Multiple degradation-driven preventive maintenance policy for serial-parallel multi-station manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    6. Xia, Tangbin & Si, Guojin & Shi, Guo & Zhang, Kaigan & Xi, Lifeng, 2022. "Optimal selective maintenance scheduling for series–parallel systems based on energy efficiency optimization," Applied Energy, Elsevier, vol. 314(C).
    7. Liu, Gehui & Chen, Shaokuan & Ho, Tinkin & Ran, Xinchen & Mao, Baohua & Lan, Zhen, 2022. "Optimum opportunistic maintenance schedule over variable horizons considering multi-stage degradation and dynamic strategy," Reliability Engineering and System Safety, Elsevier, vol. 225(C).
    8. Shen, Yilan & Zhang, Xi & Shi, Leyuan, 2022. "Joint optimization of production and maintenance for a serial–parallel hybrid two-stage production system," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    9. Yishuang Hu & Yi Ding & Zhiguo Zeng, 2022. "Redundancy optimization for multi-state series-parallel systems using ordinal optimization-based-genetic algorithm," Journal of Risk and Reliability, , vol. 236(1), pages 66-78, February.

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